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  1. Home >
  2. Technologies & Solutions >
  3. Chlor-Alkali
Technologies & Solutions

Chlor-Alkali

  • Overview
  • Applications

The Chlor-Alkali process is an industrial technology for the electrolysis of sodium chloride (NaCl) or potassium chloride (KCl). This technology is used to produce chlorine (Cl2), sodium hydroxide (NaOH, caustic soda) or potassium hydroxide (KOH, caustic potash) and hydrogen (H2), which are commodity chemicals required by industry.

CHLOR-PACK®: SMALL CHLOR-ALKALI UNITS FOR "ON SITE" PRODUCTION

Consito developed know-how and technologies for small scale chlor-alkali units, 1 to 15 MTPD chlorine capacity, in order to provide for a reliable, highly efficient device to produce "on site" chlorine, 32% caustic soda/caustic potash and hydrogen.
The availability on site of such products eliminates the risks associated with their transportation and storage especially in countries with high ambient temperature.

Our small scale plants, named CHLOR-PACK®, are pre-assembled, modular skid-mounted electrolysis units, based on bipolar membrane cells. They can be equipped with transformer-rectifier, brine preparation, brine purification, depleted brine dechlorination, automatic control.

Chlorine gas can be dried and compressed to be fed directly by pipeline to the consumers or liquefied under pressure and stored.
We can supply falling film evaporators for caustic soda/potash concentration up to 50% or to flakes.
Alternatively, chlorine and caustic soda can be directly converted to sodium hypochlorite ("bleach") in a further step of our plants or to hydrochloric acid.

CHLOR-PACK® process

CHLOR-PACK® is a pre-assembled, modular skid-mounted electrolysis unit, based on bipolar membrane cells, the most flexible and less expensive membrane electrolysis device, where the salt brine solution is transformed to chlorine, caustic soda and hydrogen, according to the following reaction:

2 NaCl + 2 H2O = Cl2 + H2 + 2 NaOH

Bipolar membrane cell is the main component of packaged, preassembled electrolyzers in small plants for production of caustic and chlorine from salt.
The cells can be assembled in a standard module in a wide range of arrangements. Moreover, each module can be equipped with its own rectifier, or, if the customer's requirements concerning the maximum circuit voltage are matched, it is also possible to get the required production arranging in series several modules fed from a single rectifier.

Our electrolysis units can includes the following stages:

  • Brine preparation: saturation dissolving of rock salt, vacuum salt or solar salt
  • Brine purification: softening and filtering
  • Brine super purification: ion-exchange resins
  • Membrane electrolysis, including transformer and rectifier installation
  • Depleted brine dechlorination
  • Cooling, filtering, drying, compression, liquefaction and storage of chlorine
  • Cooling and drying of hydrogen
  • Caustic evaporation up to 50% or flaking
  • Chlorine absorption system: emergency absorption or with hypochlorite synthesis
  • Sludge filtering

CHLOR-PACK® operating data

Raw materials of the electrolysis are salt (NaCl or KCl) and water (H2O).
Sources of salt include sea water (solar salt NaCl), mineral deposits (rock salt NaCl or KCl) or salt produced by brine evaporation (vacuum salt NaCl or KCl).
Membrane grade caustic in the form of a 32 % NaOH solution or 29 % to 32 % KOH solution, hydrogen gas and chlorine gas are the primary products obtained in our CHLOR-PACK®.

Production
Cl2 MTPD 1 to 15
NaOH 32% (as 100%) MTPD 1.12 to 16.8
Hydrogen t/tCl2 0.028
Single cell voltage V 3.5
Operation amperage kA/m2 4.0
Current efficiency % 93
Raw materials & utilities
Solar salt (NaCl 98%) t/t Cl2 1.83
HCl (32%) kg/t Cl2 1.8
Sodium bisulphite or H2O2 (dechlorination) kg/t Cl2 <10
NaOH (32%) (precipitation) kg/t Cl2 39
Na2CO3 (precipitation) kg/t Cl2 40
Process water (caustic) m3/t Cl2 1.03
Process water (dissolving) m3/t Cl2 1.73
DC power kWh/t Cl2 2,600
Effluents
Liquors, sludge kg/t Cl2 522
Solids, sludge kg/t Cl2 131
Open table

CHLOR-PACK® features

  • "On site" production
  • No risks for transportation and storage
  • Low energy consumption
  • No environmental pollution by mercury or asbestos
  • High product purity
  • Ease of handling and operation
  • Low investment and operating costs


Chlor-alkali applications

Large quantities of chlorine and caustic are required as key chemicals for a wide range of end products, for the following industries:

  • Chemical industry
  • Pulp and paper industry
  • Inorganic chemicals for waste water and drinking water treatment
  • Petrochemical and plastics industry (e.g. for VCM, PVC, TDI, MDI, Epichlorohydrin)
  • Industry with a high caustic soda demand such as of Aluminium and Pharmaceutical industry


EVAPORATION & CRYSTALLIZATION SYSTEMS FOR CHLOR-ALKALI UNITS

Beside the small scale chlor-alkali units, 3V Tech's Mabo Division designs and supplies tailor-made evaporation/crystallization plants for the chlor-alkali industry, also for large capacities, which can be arranged as skid-mounted units or suitable systems for on-site installation:

  • Vacuum salt crystallization (brine from wells)
  • NaOH/KOH evaporators from 31-33% to 50%, from 50% to 73% or to 98-99,5% flakes
  • Depleted brine evaporators (NaCl/KCl re-saturation) from 190-200 g/l to 300-310 g/l
  • Sodium sulfate (purging) recovery and crystallization
3V Tech S.p.A.
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24121 Bergamo
Italy
+39 035 0761 311
info@3v-tech.com
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